Process for producing molded laminated articles

ABSTRACT

A PROCESS FOR PRODUCING A LAMINATED PRODUCT COMPOSED OF A PLURALITY OF LAYERS OF STRETCHABLE PAPER BONDED TOGETHER BY INTERPOSED LAYERS OF A RESIN WHICH HAS A SATURATING CONSISTENCY WITH RESPECT TO THE PAPER LAYERS EITHER AS APPLIED OR DURING CURING, A PULVERULENT FILLER MATERIAL BEING ADDED TO THE RESIN IN A QUANTITY SUCH THAT THE CURED PRODUCT IS CHARACTERIZED BY THE RETENTION OF A DISCRETE LAYER OF RESIN BETWEEN ADJACENT PAPER LAYERS WITH LIMITED PENETRATION OF THE RESIN INTO THE PAPER LAYERS.

Aug. 22, 1972 PROCESS FOR R. c. FRICK ETAL 3,686,054

PRODUCING MOLDED LAMINATED ARTICLES Original Filed Aug. 10, 1962 Fig. 3

INVENTOR/S FoYaFelc/z AND V/cTo/e E. CALVIN,

JOHN C. SHARPE 4ND W/LL/AM W. Pow/E BY k%a44a, anal W210 ATTORNEYSUnited States Patent filce 3,686,054 PROCESS FQR PRODUCING MOLDEDLAMINATED ARTICLES Roy C. Frick, Victor E. Calvin, John C. Sharpe, andWilliam Wallace Rowe, Lockland, Cincinnati, Ohio, assignors toCincinnati Industries Inc., Cincinnati, Ohio Original application Aug.10, 1962, Ser. No. 216,204, now Patent No. 3,483,071, dated Dec. 9,1969. Divided and this application Oct. 22, 1969, Ser. No. 871,148

Int. Cl. B29c 11/00; B32!) 3/28, 31/06 US. Cl. 156-224 11 ClaimsABSTRACT OF THE DISCLOSURE A process for producing a laminated productcomposed of a plurality of layers of stretchable paper bonded togetherby interposed layers of a resin which has a saturating consistency Withrespect to the paper layers either as applied or during curing, apulverulent filler material being added to the resin in a quantity suchthat the cured product is characterized by the retention of a discretelayer of resin between adjacent paper layers with limited penetration ofthe resin into the paper layers.

This is a division of copending application Ser. No. 216,204, filedAugust 10, 1962 and entitled Molded Laminated Articles and Process ofProducing Them, now US Pat. No. 3,483,071, dated Dec. 9, 1969.

In a copending application of Larrabee, Calvin and Frick, Ser. No.857,133, filed December 3, 1959, and entitled Laminate and ArticlesProduced Therefrom, now abandoned there is described a product made upof universally stretchable webs and alternating layers of thermoplasticresin in a molded or deformed condition. The universally stretchablewebs are generally webs of doublediagonally creped papers as hereinafterset forth. The thermoplastic layers are of such character that they arenon-extensible at room temperature, but are capable of being heated to atemperature at which they are rendered extensible without becoming sosoft or liquid as to attain a strongly saturating consistency. Laminatescan be made up of alternate plies of the Webs and thermoplastic layers,the laminates being pre-plied under heat sufficient to cause the filmsto bond to the external fibers of the webs without being wholly absorbedinto the webs. The result is a laminate consisting of gathered paperWebs in a substantially unsaturated condition interleaved with layers ofresin, which layers are non-extensible at room temperature. The productis characterized by extraordinary stiffness in proportion to itsdensity.

Such laminates, under conditions of heat, may be distorted to form awide variety of hollow articles without losing their essentialcharacteristics. The distorting may be done in closed molds, open moldsand single molds. In most cases the laminate extends beyond the moldcavity or mold ring and is subjected to peripheral restraint. By singlemolds is meant such structures as those in which the peripherallyrestrained laminate is displaced by a plunger-like element engaging itupon one side, with or without fluid pressure on the other side, thosein which the laminate is expanded to fill a recess in a hollow member byfluid pressure (inclusive of both vacuum and superatmosphericpressures), and various combinations of these expedients. The termclosed mold is used to indicate a deforming means having matching femaleand male mold members engaging opposite sides of the laminate, buthaving also means for pinching off or cutting off any extending portionof the laminate when the mold parts are fully seated. The term open moldis used to designate a deforming means having matching male and femalemold 3,686,054 Patented Aug. 22, 1972 members but without thecutting-off feature. In other words, when the mold parts of an open moldare fully seated, there will still be a peripheral space between them,through which peripheral space the laminate extends.

The essential characteristics referred to above contemplate theexistence in the formed laminate of discrete masses, webs or films ofthe thermoplastic substance bonded to but lying between layers of thepaper webs. As has been indicated, the deformed laminates exhibit thesurprising combination of great strength and rigidity with a low densityor specific gravity. It is believed that this result is due to thetrussing coaction of the non-extensible films or masses with the paperwebs, which webs are themselves extensible but strongly resist internaldisruption. The distorted laminates of the copending application arerelatively inexpensive, and are also free from brittleness, having somedegree of resiliency.

One of the objects of the present invention is the provision of animproved mode of making a structure generally similar to that describedabove, but one in which the penetration, or lack thereof, of the webs bythe resin is controllable.

It is an object of the invention to provide a method and means forretention of enough resin between the surfaces of the adjacentstretchable webs of a laminate to achieve lamination and to preventdelamination even when the characteristics of the resin, and the resinto paper ratio, are such that under molding conditions the necessaryquantity of resin would not normally be so retained.

Another object of the invention is the provision of a process of makingan article of the class described using thermosetting resins or resinswhich initially are substantially liquid and tend to be absorbed intothe paper Webs, or which attain a substantially liquid stage attemperatures desired to cure the resin.

The above stated objects have not hitherto been possible with suchresins for the following reasons. If there is insufiicient resin tosatisfy the absorptive characteristics of the webs, then the resin islikely to be absorbed by the webs to the extent of preventing laminationor permitting delamination because there is insufiicient resin retainedbetween the surfaces of the adjacent webs. On the other hand, if thereis an excess of the resin over that required to saturate the webs in thefinal product, then the resin becomes the continuous phase, containingthe fibrous Webs, as it were, in suspended condition. The strength ofthe product may increase, but so also will density and cost. Moreover,the product acquires the brittleness characteristic of cured high resincontent bodies even when reinforced.

Thus, an important object of the present invention is the provision of amode of operation in which a resin which is initially liquid or becomesliquid under heat can be caused to remain in large measure between thefibrous plies in a laminated article.

It is an object of the invention to provide a laminate of such characterthat distortion in an of the operations referred to above is notdependent upon the prior attainment of an elevated temperature to rendernon-extensible films or layers extensible. In the practice of theprocess of this invention, the resin does not become set or cured untilafter the deformation of the laminate.

It is an object of the invention to provide a product having greatrigidity and heat resistance coupled with densities lower than thoseobtained by molding filled resins alone or by molding resinous laminatesin which the laminate becomes saturated.

It is an object of the invention to provide a method of rendering one ormore plies of a laminate impervious to gas, so that fluid pressure maybe used in the molding if desired.

It is an object of the invention to provide improved modes of securingsurface ornamentation on laminates and articles made therefrom.

These and other objects of the invention which will be set forthhereinafter or will be apparent to one skilled in the art upon readingthese specifications, are accomplished by those procedures and in thoseproducts of which certain exemplary embodiments will now be described.

Reference is made to the accompanying drawings where- FIG. 1 is adiagrammatic illustration of one form of apparatus upon which initiallaminates can be made in the practice of this invention.

FIG. 2 is a diagrammatic illustration of one form of single mold of thesocalled ring and plug type, with further diagrammatic illustration ofcertain parts of a press in which the mold is used.

FIG. 3 is a diagrammatic illustration of another form of single mold.

The products of this invention are made from resin absorptive webs andresinous thermosetting materials. If the products of this invention areto be formed, the webs must be stretchable. Without limitation, they arepreferably webs which have been creped in two substantially oppositedirections in accordance with the teachings of one or more of thefollowing patents:

W. C. Kemp No. 2,008,181, issued July 16, 1935 W. C. Kemp No. 2,008,182,issued July 16, 1935 W. C. Kemp No. 2,071,347, issued Feb. 23, 1937 W.W. Rowe No. 2,399,256, issued Apr. 30, 1946 P. W. Dorst No. 2,494,334,issued Jan. 10, 1950 W. W. Rowe No. 2,567,967, issued Sept. 18, 1951 W.W. Rowe No. 2,610,935, issued Sept. 16, 1952.

The best webs for the purpose are webs of paper or cloth. These arefibrous in nature and can be saturated or penetrated to any degreedesired or kept substantially unpenetrated through employment of theteachings of this invention. Various basis weights of paper may beemployed, and the creped product may be made quite uniform in character,with very small creping crinkles or rugosities despite a large amount ofresident stretchability. In accordance with the teachings of the lastmentioned patent above, the paper product may be made substantiallysmooth on one side. In the preferred creping operations a positivecreping adhesive is used; but since it is preferably small in amount, itmay be disregarded for purposes of the following description.

In the manufacture of laminates and molded articles characterized bygreat strength and rigidity coupled with low density, the chief problemarising from the use of thermosetting or other resins which areinitially penetrating or which attain a liquid character under thetemperatures involved in the process is to hold an adequate quantity ofsuch resinous substances in discrete layers between the plies of fibrousstretchable webs. This problem is solved in the present invention by theuse of filler substances in the resins, the filler substances being ofsuch character as to remain between the fibrous webs in a resin coatedcondition.

The pressure used during the molding or forming operation and the meansof applying the pressure also are important in determining the depth ofpenetration of the resin into the fibrous webs. To control thispenetration single molds with fluid back pressure, such as air pressure,are preferred. Fluid back pressure provides a uniform pressure on allareas and eliminates problems that would be imposed by the predeterminedclearances of matching molds and the differential stretching andthinning of the peripherally restrained laminae.

Various thermosetting resins may be used. As illustrative examplesmentioned may be made of the phenolaldehyde, melamine and urea-aldehydetypes of resins, all of which are well known in the art.

However, a resinous substance is preferred which not only is liquid atroom temperature in the uncured state, but which is substantially freeof volatile substances and does not generate substantial quantities ofsuch substances during curing. The term reactive is employed by thetrade in connection with such resins. Preferred 100% reactive resinsinclude the epoxies and the polyesters.

The use of fillers is not new. Wood flour filler has been mixed withphenolic resin to make molding powders and powdered chalk has been addedto polyester resin as an extender. However, in the latter instance theresinous mixture has penetrated through and around the reinforcingmaterials that have been used, such as mats of glass fibers. The fillersubstances have been used for the purpose of extending or reinforcingthe resin.

The filler material should be a finely divided substance which iseconomical and which will hold the desired quantity of resin between thesurfaces of the laminae. We have used nonabsorptive mineral fillers,such as chalk, absorptive infusorial earth, such as Dicalite, andabsorptive vegetable fillers such as wood flour and powdered cork. Thepreference is for mineral fillers. A filler having a mesh size of about99% through 300 mesh screen has been found satisfactory; and theparticle size of the filler should be such that the resin coated fillermaterial will not substantially penetrate the fibrous web, but will befiltered out be the web and remain largely between the laminae with thefiller particles coated with resin.

For purposes of the present invention, a mixture of liquid polyesterresin and mineral filler has been found very satisfactory. The quantityof the filler can be varied, but it should lie substantially in therange of /2 to 2 pounds of filler to one pound of the resin withnonabsorptive fillers such as chalk. With absorptive fillers such asinfusorial earth the quantity of filler should be substantially in therange of to 4 pound of filler to one pound of the resin.

In the exemplary form of the invention, a mixture is made of liquidpolyester resin and chalk in the percentage set forth above; and a heatcatalyst is added to the mixture in a quantity of about 1 to 2%. Thefinal mixture is of such consistency that it may easily be knifed ontothe surfaces of the stretchable fibrous webs. Any suitable heat catalystmay be employed as known in the resin art. A preferred heat catalyst foruse with a liquid polyester resin is benzoyl peroxide.

In one aspect of the practice of the invention, a lay-up or pre-laminateis made prior to the actual molding. For purposes of illustration, themixture of polyester resin and chalk disclosed in the precedingparagraph will be referred to here, it being understood that thismixture does not constitute a limitation on the invention. Also forillustrative purposes only, the manufacture of a particular kind ofmolded article, namely, a luggage shell, will be described. A luggageshell is a hollow article adapted to form (with or without additionalmolded parts), a portion such as a hinged half of a suitcase or likepiece of luggage. The article was chosen because it is a structurerequiring a substantial distortion of the material in the nature ofstretching or drawing, while at the same time it illustrates theadvantageous use of corner reinforcements as hereinafter described.

In the exemplary procedure, referring to FIG. 1, the universallystratchable web material 1 may be withdrawn from a roll 2 as requiredand carried under a knife or doctor 3 while being supported on theopposite side by a table 4 or other structure having a planar surface.The resinous mixture to which reference has been made is delivered byvarious means well known to the art, as at 5 to the bight between thedoctor and the creped paper web; and the movement of the web beneath thedoctor will serve to spread a controlled layer of the resinous mixtureon the surface of the web. Movement of the web may be accomplished by adrive roll 11 and rider rolls 13. A dry uncoated edge for the riderrolls is provided by dams which confine the resinous mixture to thatarea of the web which is to be coated. Beyond the doctor there is aknife 6 which is used to cut the coated stock into sheets of therequired dimensions. The sheets may be transferred by hand or otherwiseto an assembly table 7, where the individual sheets are laid up one uponthe other to form a prelaminate 8 of the desired number of plies. Itwill be apparent that a multiple web coater may be used if desired.

The adhesive nature of the resinous composition causes the plies tocling together. Where reinforcement is desired, as at the rounded anddome-like corners of a luggage shell, reinforcing materials may beinterleaved between the plies preferably in the form of reduceddimension pieces as illustrated at 9. The reinforcing materials areWeb-like materials inclusive of paper, cloth, mats of glass fibers orother fibrous materials, organic or inorganic in character, and thelike.

If the reinforcing materials are not such as will be penertated by theresinous mixture, it will be obvious that they should be coatedtherewith so as to provide, all over the surface of one lamina and itsreinforcements, a resinous coating to bind the next succeeding ply.Where tightly woven glass cloth reinforcing materials are used, or otherreinforcing materials difficultly penetrable by the resinous mixture,they may be precoated with resinous material.

Many reinforcing materials, however, are of open work construction sothat the resinous mixture on the surface of a lamina will strike throughthem, rendering extra coating operations unnecessary. Thus excellentresults have been obtained by using reinforcements 9 of open mesh glasscloth. The resinous mixture on the underlying ply of the laminate 8strikes through the meshes of the cloth and makes immediate adhesiveunion with an overlying ply. There may be enough distortability in arelatively small piece of reinforcing web material to permit it toconform to the general shape of the ultimate article even though it isnot gathered for stretchability.

Another way in which reinforcement can be accomplished is by thelocation at selected positions of an extra thickness of resin orresinous mixture, applied in any suitable way.

In making up a laminate, reinforcement means may be incorporated betweenany two adjacent plies or between all adjacent plies, as well asexternally, as may be required by the usage to which the article will beput. External reinforcements can be applied after forming.

By way of illustration but without purpose of limitation, a pre-laminateor lay-up for the specific purpose set forth may be made up of 165 poundbasis Weight of double-diagonally creped paper having lateral andlongitudinal stretchabilities sufficient for the draw which is to bemade in the laminate, the paper laminate being coated with about 200pound basis weight of the resinous mixture. The basis weight referred toherein is the weight per 3000 square feet, equivalent to 500 sheets, 24by 36 inches. The number of laminae may be determined by the dimensionsof the final article and the required strength and stiffness therein.The top lamina may be a web of uncoated paper. The lay-up ofpre-laminate is then transferred to a press, equipped with a single moldand fluid back pressure, and with the aid of a rubber blanket as abarrier, is formed into the desired shape and cured as hereinafterdescribed.

Matching molds may be used but they are much more expensive than singlemolds. When forming a peripherally restrained lay-up differentialstretching and thinning takes place. Thus the predetermination of theclearance between the two members of matching molds, in order to obtainuniform pressure over the entire formed product, is extremely difficult.Also, additional molds are required for different thicknesses of formedproducts. Single molds with fluid back pressure overcome theseobjections because uniform pressure is assured and one mold can producea given formed product in any thickness desired.

Since the preferred molding or distorting operations practiced inconnection with this invention are primarily stretching operations, andfor reasons stated above, various forms of single molds are preferred.Referring to FIG. 2, a molding apparatus is shown comprising a presshaving a platen 16. On this platen there is shown a hollow member orchase 17 which is not a molding member but is a support. The edges ofthe pre-laminate or lay-up 12 are supported by a molding ring 18superposed on the chase 17. Edge portions of the pre-laminate areclamped against the top surface of the hollow member in any suitableway, but preferably by a holding ring 19.

The distortion is accomplished by a single mold member 20 passingthrough the ring 19 and the molding ring 18, and distorting thepre-laminate as shown in dotted lines. Relative movement of the plungerand the hollow member and the molding ring is effected by means of thepress, which is powered hydraulically, mechanically or by air. Anhydraulic cylinder and piston indicated generally at 21, may be mountedbetween the base 22 of the press and the platen 16. The platen may beslidable on the usual press frame rods 23 which connect the base withthe top element 24. The single mold member or plunger 20 is mounted onthe top element 24, and will have electrical or fluid connections (notshown) for the application of heat. The holding ring 19 may be springpressed as at 25 from the top element. Such stop means for limiting therelative motion of the platen and plunger as well as for lifting theholding ring may be provided as desired. Since such elements are wellknown to the worker in the art they have not been illustrated in thediagrammatic showing of FIG. 2. Fluid back pressure may be utilized bysealing the chase 17 against leakage and introducing air, or othersuitable fluid, through ports in the chase. A rubber blanket or otherstretchable material, as hereinafter described, may be utilized as abarrier for the fluid pressure. It will be understood by one skilled inthe art that the position of the molding elements may be inverted inFIG. 2 so that the male member 20 will be positioned below theprelaminate.

Yet another form of single mold structure is illustrated in FIG. 3. Herethe mold member 26 has a molding cavity 27 for determining the desiredfinal shape of the article. The pre-laminate or lay-up 28 is placed overor against the mold element 26 and the edges of it which project beyondthe cavity 27 are clamped in position by a holding ring 29 or othersuitable means. Instead of employing a plunger to distort the material,the pre-laminate may be deformed and caused to conform to the surfacesof the cavity by fluid pressure. One may apply fluid presure such as airpressure against the side of the pre-laminate opposite the cavity, orone may add a vacuum between the cavity and the prelaminate bywithdrawing air through ports in the member 26, one of which isindicated at 30,.

Where the pre-laminate is not itself impervious to fluidpressure, resortmay be had to the use of an imprevious blanket 31 of rubber or otherstretchable material.

Fluid pressure is a requirement of the process as shown in FIG. 3because there is no male member to form the material. Consequentlysufficient fluid pressure, such as air, must be applied to fully formthe resinous coated fibrous plies into the cavity. The amount ofpressure necessary will depend upon the shape that is to be formed plusthe resistance -to stretch forming of the plies and the number of plies.As an example, but without purpose of limitation, with a 60:40 chalk toresin ratio and a 40:100 ratio of resin to paper, pressures from to 200psi. have been used successfully while still retaining cross sectionalareas of the fibrous webs free of resinous penetration. Greaterpressures may result in complete penetration but enough filled resinwill remain between the laminae to accomplish proper bonding of thelaminae even when the resin to paper ratio is low.

On the other hand, much lower back pressure may be successfully used inthe process as shown in FIG. 2. Commercial products have been made byusing a rubber blanket or a sheet of thermoplastic film (not shown) onthe side of the lay-up opposite to the male plunger. The very lowpressure exerted by the stretch forming and resultant tensioning of sucha blanket or film is sufiicient to provide and retain the contact thatis necessary for lamination. Such a rubber blanket or thermoplastic filmwill also provide the barrier that is necessary if fluid pressure is tobe used.

It has been found, however, that physical properties such as deflection,corner compression and impact fatigue, are improved with the use ofincreased back pressure. Normally air back pressure in the range from to50 psi. is employed.

The mere distortion of the preferred pre-laminate above described doesnot require the use of heat as has already been indicated. This permitsthe distortion to start upon the proper location and clamping of theprelaminate or lay-up in the molding apparatus. It will be understoodthat heat is required for the curing of the resin. Consequently, heatwill be applied to the single mold elements of FIGS. 2 and 3. This maybe done by electrical or fluid heating means (not shown) in ways wellunderstood by the worker in the art. The molded or distorted articlewill be left in the mold until sufiicient cure of the resin has beenaccomplished to enable the article to retain its final shape. The fluidelement may also be heated.

It will be understood, that if the male element 20 of FIG. 2 is providedwith a recess in its molding surface, sufiicient back pressure may beapplied to cause the prelaminate to enter this recess. In this way themolding procedures described in connection with FIGS. 2 and 3 have beencombined.

In the prior art luggage shells and some other articles have beencovered on the outer surface with materials of a decorative nature,formed and afiixed to the shell after manufacture is otherwisecompleted. It is an advantage of the process of this invention, however,that decoration may be accomplished as a part of the process, making asecond and separate operation unnecessary. The outer paper web of thelay-up may be given a surface finish prior to making the lay-up. Theterm surface finish as here used is inclusive of physical textures suchas may result from creping or embossing, and of coloration or patterns,such as may be formed by printing or equivalent procedures, and of theprovision of overlying films, clear or colored, opaque or transparent,imposed upon the product for the sake of appearance, and/or protection,and forming part of the laminate. Any thermoplastic film which iscapable of stretching to accommodate the draw, may be used, such aspolyvinyl chloride. With limited depths of draw, printed or coloredcloth may also be used.

It is an advantage of the invention that webs having pre-formed surfaceconfigurations may be employed for surface decoration, such webs beingattached to the laminate before or during the distortion or molding ofthe laminate to form the final article. The double-diagonally crepedpaper webs which are preferably used in the practice of this inventionlend themselves very well to the production of surface textures byembossing. For example, by means of a suitable platen press and dies, orby means of suitably configured rolls, the universally stretchable paperwebs may readily be given textures simulating cloth and different formsof leathers, as well as other configurations of a decorative orarbitrary character. The surface texture of a gathered web showing smalland evenly distributed creping crinkles is pleasing in itself and blendsvery well with printed designs such as representations of woven clothand the like.

The webs, prior or subsequent to embossing, may be colored or printed.It has been found, that if a colored or printed web, which may also be atextured web, can be covered with a transparent film of thermoplasticsubstance, the appearance of the product is not only greatly enhanced,but the film acts as a barrier to liquids and gases, as well ascontributing to the wear resistance of the product. It is also possibleto use a colored film, opaque or transparent, over an uncolored,textured web. The problem is to cause such a film to adhere and conformto the underlying textured surface without destroying or impairing thesurface texture of the web. In the prior art, films have been adhered tounderlying webs by the use of heat and/ or adhesives plus positivepressure applied by the use of rolls or press platens. The use of any ofthese procedures tends to destroy any texture previously imparted to theunderlying Web. Further, if a film were adhered to an underlyingtextured web during a forming and laminating process while usingmatching molds, the texture previously applied would tend to bedestroyed due to the predetermined clearance between the mold members.This problem may be overcome and a thermoplastic film adhered to thesurface of a textured web which forms the top lamina of a lay-up byutilizing a combination of temperature, time and fluid pressure, asfollows. It has been found that, during the process of making a formedlaminated article using single molds and fluid back pressure, thecombination of a temperature suitable to soften the plastic, with thetime element necessary for curing the resinous mixture, and theapplication of fluid back pressure will cause an overlying thermoplasticfilm to adhere and conform to the surface texture of the web underneathit while preserving the surface appearance and texture of the underlyingweb.

Such an overlying film should be impervious to gases or liquids in orderto provide the barrier necessary for the use of fluid back pressure.Examples of thermoplastic films that may be used are polyvinyl chloride,polyvinylidene chloride, polyethylene, polypropylene, videne, Mylarbacked with polyethylene and acrylonitrile-butadiene-styrene.

In this procedure, heat may be employed sufficient to render thethermoplastic film tacky so that it will adhere to the surface of thepaper layer; but it is also possible to assist adhesion by precoatingthe top paper lamina with a heat-sensitive adhesive compatible with theoverlying thermoplastic film. For example, when the overlying film isvinyl the top paper lamina my be precoated with a dispersion ofpolyvinyl chloride (such as those sold under the trademark Geon).

The same combination of temperature, time and fluid pressure makes itpossible to join to the top lamina of a lay-up an unsupported film ofthermoplastic resin such as vinyl which has been pretreated by embossingor otherwise to give it a textured surface. In the handling of texturedfilms in accordance with this procedure, it is generally advisable toemploy an adhesive as described above; although depending upon thenature and thickness of the thermoplastic film an adhesive may sometimesbe dispensed with. It is also possible to use a supported film which hasbeen adhered to a universally stretchable web and textured, and toadhere this laminate to the lay-up by means of the thermosettingresinous mixture.

When using a pre-textured film, whether it is unsupported or supportedby a backing, it is preferable to have the texture predominantly onesided, that is, having one relatively smooth side and one textured sideso that the caliper is appreciably greater at the peaks of the texturethan it is in the valleys. This type of texure is more resistant to lossof appearance under the stretching and elevated temperatures involved inthe forming and curing operation.

In the manufacture of the laminated products to which this invention isprimarily addressed, the use of a filler substance in the thermosettingresin employed for laminating purposes holds the resin in a positionbetween the plies of gathered webs. This is to say, the resin coated 9filler material as a layer cannot enter into plies, and it holds in aposition between the webs that amount of the thermosetting resin whichis required to achieve proper bond between the fibrous layers in thelaminate, irrespective of the fact that during the molding operation atleast the thermosetting resin itself attains a thinly liquid saturatingcharacteristic.

Heretofore, when using resins which are initially of a consistency thattends to saturate fibrous webs or which reach such a consistency underthe temperatures and pressures desired during the curing operation, ithas been diflicult to achieve good lamination when low resin to paperratios and low pressures are employed. This has been so because therelatively small amount of resin penetrates and absorbs into the fibrouswebs leaving an insuflicient amount on the surface of, or between thelaminae. Therefore, relatively high resin contents and relatively highpressures have been used to insure good adhesion. Thus the products ofthe prior art are dense and costly. They are also relatively brittle.One versed in the art is aware that a low resin content, within thereinforcing laminae, is desirable for increased impact strength.

By the procedures above described, it has been possible to achievepositive adhesion between the plies with low resin content, while usinglow pressures. The reinforcing webs can be kept substantiallyunsaturated and unpenetrated. As an example, but without purposes oflimitation, products are being commercially produced using five plies ofuniversally stretchable paper, combined basis weight of 825 pounds,coated with four layers of resinous mix, combined basis weight of 800pounds and consisting of a chalk to resin ratio of 60:40, thus having apaper to resin ratio of 100:38.8. These products are formed, laminatedand cured by the process as shown in FIG. 2 and hereinabove describedusing air back pressure of to 30 p.s.i. The importance of uniformpressure and the preference for single molds has already been indicated.By using these procedures a quantity of resin is held between the paperplies and upon hardening through cure forms a non-extensible rigid layerbetween each pair of paper plies.

The products just described have a relatively low density withsurprising rigidity and strength and are not brittle. Cross sectionalareas of the paper laminae remain substantially nnpenetrated by theresin. If a non-brittle product, slightly higher in density butpossessing greater strength is desired, it is possible to achieve aregulated pentration of the resin into the paper plies by increasing theback pressure. Referring to the previous example, an increase of backpressure to the range of 200 to 300 psi. would result in penetration ofthe resin throughout the paper laminate in a controlled and low amountwhile still retaining the layer of resinous mixture between the plies.

It is also possible to provide for the penetration of a controlledamount of resin into the laminae by a reduction of the amount of fillerin the resinous mix while retaining the same amount of resin. In theprevious example, if the filler content was reduced from 60% to 33% ofthe resinous mix and the resin to paper ratio remained the same,penetration of the resin into the paper in a controlled and low amountwould occur at back pressures in the range of 100 to 200 psi, whileretaining a layer of the resinous mixture between the plies.

Through the teachings of this invention it is possible to make productspossessing good lamination and surprising strength and rigidity withpaper to resin ratios as low as 100 to and with back pressures lowerthan 10 p.s.i.

Comparative tests made on products of this invention (containing afiller such as chalk in the resin) as against products made from thesame materials but without the chalk, exhibit superior physicalqualities including corner compression values and impact fatigue values.

The strength characteristics of the products of this invention may beincreased by increasing the thickness of the layers of filled resinlocated between the paper plies, while retaining low density as comparedwith saturated products.

In commercial practice the coatings of filled resin of the chalkpolyester type hereinabove described, have generally ranged from poundsto 350 pounds per 3000 square feet, using filler to resin ratios of66:33 to 33:66 and paper to resin ratios as low as 100:25. However, thisis not a limitation since coats and ratios outside of these ranges havebeen used successfully.

EXAMPLE I A mixture was made of liquid polyester resin and a filler oflimestone or chalk in weight proportions of 1:1. This mixture containeda catalyst and was capable of being rapidly hardened to an infusiblecondition under heat. Universally stretchable creped kraft paper havinga basis weight of pounds was coated with the mixture of polyester andfiller, the application being of pounds per 3000 square feet. The coatedpaper was cut into sheets of a desired size and these sheets were laidup one on top of the other, on a table to form a pre-laminate comprisingat least five layers of coated web. Reinforcements were used at selectedpositions as hereinabove described. A final top sheet was placed on thecoated surface of the top laminae. This sheet was a sheet of universallystretchable paper of the same basis weight, coated with a layer ofpolyvinyl chloride and embossed to provide a desired texture.

The pre-laminate, or lay-up, which adhered together by reason of thetacky condition of the resinous mixture, was transferred to a pressequipped with a single mold of the plug and ring type, as shown in FIG.2. The plug was heated to a temperature sufficient to cure the resin,and the lay-up was formed under a pressure sufiicient to deform it tothe desired shape. The deformation can best be described as an operationanalogous to the drawing of metal.

The exposed layer of the laminate was then subjected to a positive fluidback-up pressure of air at about 30 p.s.1.

The result of the operation, after the resin was cured in the press andthe excess peripheral portion of the lami nate was trimmed away, was aluggage shell having a depth of something more than two inches. Theshell was strong and had a high degree of stiffness, although itsspecific gravity was only 1.1 to 1.2. The textured surface was retained.

It will be understood that the power or mechanical pressure required todeform the pre-laminate or lay-up, will be subject to variation due tothe number and thickness of the plies in the structure. The back-uppressure will be sufficient to insure that all layers are pressed andcured in contact with each other.

EXAMPLE II A similar laminate was made up excepting that its top layerwas a layer of multilaterally stretchable creped kraft paper in nncoatedcondition and not textured, This was molded as above described; butsince the surface layer was not impervious to gas, the back pressure wasexerted on it through the intermediary of a rubber blanket or membrane.The molded article had substantially the same physical characteristics.

EXAMPLE III A laminate similar to that of Examples II was laid acrossthe cavity of a female mold member in a press, and clamped about theedges of the mold cavity. The central portion of the laminate was drawninto and caused to conform to the cavity of the female mold member byfluid pressure exerted on the side of the laminate opposite the cavitythrough the intermediary of a rubber blanket. The mold member was heatedto cure the thermosetting resin.

The result was a luggage shell having substantially the samecharacteristics as those described above.

1 1 EXAMPLE rv Pre-larninates or lay-ups were made and pressed as setforth in Example II, but including a pre-embossed film of vinyl chloridelaid over but not adhered to the outermost ply. The outermost paper ply,next to the vinyl film, was coated with Geon. The result was a luggageshell having substantially the same physical characteristics as thosedescribed above and possessing a textured vinyl surface. It was notnecessary to use a rubber blanket because the vinyl film was imperviousto the passage of fluid, such as air.

EXAMPLE V A lay-up was made as in Example IV, excepting that an outerply of the paper bore a decorative printing and the texture imparted bycreping. This outer ply was covered with a thermoplastic film ofpolyvinyl chloride which was clear and unembossed. Upon molding as inExample I, a product was produced which was similar in physicalcharacteristics. It had, however, a wear resistant outer coating ofpolyvinyl chloride to which had been imparted the surface texture of theunderlying paper layer. The print desi n of the underlying web wasapparent and decorative.

It was found that a similar effect could be obtained using an adhesive,e.g., when the top paper layer had been coated with a thin coating ofGeon and dried.

Modifications may be made in the invention without departing from thespirit thereof. For example, it will be obvious to one skilled in theart, that the laminates hereinabove described may be made in the form offiat panels. This is done by incorporating a layer of resin coatedfiller material between the plies, in accordance with the teachings ofthe present invention. Surface decoration may also be accomplished inaccordance with these teachings.

The invention having been described in certain exemplary embodiments,what is claimed as new and desired to be secured by Letters Patent is:

1. A process for producing a laminated product composed of a pluralityof layers of universally stretchable paper bonded together by interposedlayers of a thermosetting resin which has a saturating consistency withrespect to the paper layers either as applied or during curing, whichcomprises the steps of:

producing a mixture of said resin and a pulverulent filler material theparticles of which are coated with the resin and are of a size such thatthey will not substantially penetrate the paper layers when the resin iscured;

forming a layu'p composed of a plurality of paper 5 layers joinedtogether by interposed discrete layers of said resin and filler mixture;

deforming the lay-up so formed under sufiicient heat and pressure tocure said resin and bond said paper layers together;

the particles of filler material being present in a quantity such thatthe cured product is characterized 12 by the retention of a discretelayer of resin between adjacent paper layers with limited penetration ofthe resin into the paper layers.

2. The process of claim 1 wherein the said paper layers will filter outenough resin coated filler particles to provide a laminating layer ofresinous material even when an excess of resin is permitted to penetratethe paper.

3. The process of claim 1 wherein said lay-up is deformed in a singlemold structure.

4. The process of claim 3 wherein fluid back pressure is used to deformsaid lay-up.

5. The process claimed in claim 1 wherein said resin is chosen from theclass consisting of reactive resins comprising polyester resins andepoxy reins, wherein said resin is substantially liquid at roomtemperature in the uncured condition, and wherein said mixture of resinand filler contains also a heat catalyst.

6. The process claimed in claim 1 wherein the basis weight of the paperlayers is substantially in the range of 100 to 250 pounds per 3000square feet.

7. The process claimed in claim 1 in which the said mixture is appliedto the surface of said paper layer in an amount of substantially 124 to350 pounds per 3000 square feet.

8. The process claimed in claim 1 wherein the ratio of filler to resinin said mixture is substantially 33% 266% to 66% 133%.

9. The process claimed in claim 1 wherein an outer ply of thermoplasticfilm is superposed over a textured web and adheres to the laminatedproduct and conforms to the texture of the said web.

10. The process claimed in claim 1 wherein an outer ply of texturedthermoplastic film is superposed over an external web and adheres to thelaminated product and retains its texture.

11. The process claimed in claim 1 wherein a textured outer ply,consisting of a layer of thermoplastic resin combined to a supportingweb, is superposed over an external web and adheres to the laminatedproduct and retains its texture.

References Cited UNITED STATES PATENTS 1,265,132 5/1918 Stokes 161-1292,304,123 12/1942 ROWe l6l120 2,861,910 11/1958 Johnston et a1. 16l1952,987,103 6/1961 Yakubik 161-254 3,121,656 2/1964 Gluck 161158 FOREIGNPATENTS 577,676 5/1946 Great Britain.

WILLIAM J. VAN BALEN, Primary Examiner lU.S. Cl. X.R.

